- 11 - EN 50182:2001

Table 5 - Type and sample tests for conductors

Type test Sample Clause

test
Conductor - surface condition x x 6.4.1
- diameter x x 6.4.2
- inertness x x 6.4.3
- lay ratio and direction of lay x x 6.4.4
- number and type of wires x x 6.4.5
- mass per unit length x x 6.4.6
- stress-strain curve (1) - 6.4.7
- tensile breaking strength (1) - 6.4.8
- stringing test (1) - 6.4.9

Aluminium wires - diameter x x 6.5.2

- tensile strength x x 6.5.2
- elongation (2) x x 6.5.2
- resistivity x x 6.5.2
- wrapping test x x 6.5.2
- welding x - 6.5.3

Zinc coated - diameter x x 6.5.2

Steel wires - tensile strength x x 6.5.2
- stress at 1 % extension x x 6.5.2
- elongation or torsion test x x 6.5.2
- wrapping test x x 6.5.2
- mass of zinc x x 6.5.2
- zinc dip test x x 6.5.2
- adhesion of zinc coating x x 6.5.2

Aluminium-clad - diameter x x 6.5.2

Steel wires - tensile strength x x 6.5.2
- stress at 1 % extension x x 6.5.2
- elongation x x 6.5.2
- torsion x x 6.5.2
- cladding thickness/uniformity x x 6.5.2
- resistivity x x 6.5.2

Grease - mass per unit length x x 6.6.1

- drop point x x 6.6.2
(1) By agreement between the purchaser and manufacturer.
(2) Elongation test for AL1 is not required.
EN 50182:2001 - 12 -

6.2 Sample size

When agreed by the manufacturer and the purchaser at the time of ordering, tests shall be carried
out on a minimum of 10 % of the drums offered for inspection and, in such cases, each wire shall
be tested. Where the manufacturer has a demonstrated capability of meeting or exceeding the
requirements, the number of test samples may be reduced, with the agreement of the purchaser
and manufacturer, to a level which ensures that each production lot of conductor is given
adequate monitoring.

Drums to be sampled shall be selected at random, and samples taken from the outer end of the
drums.

The length of the sample of conductor taken shall be sufficient to allow all tests to be performed
on the same specimens of wire.

In order to check the grease, a sample of conductor shall be taken from one drum of each
inspection lot.

6.3 Rounding rules

The following rounding rules shall be used for determination of compliance with this standard.

6.3.1 When the figure immediately after the last figure to be retained is less than 5, the last
figure to be retained remains unchanged.

6.3.2 When the figure immediately after the last figure to be retained is greater than 5, or equal
to 5 and followed by at least one figure other than zero, the last figure to be retained is increased
by one.

6.3.3 When the figure immediately after the last figure to be retained is equal to 5 and followed
by zeros only, the last figure to be retained remains unchanged if even and is increased by one if
odd.

6.4 Properties of conductor

6.4.1 Surface condition

The surface of the conductor shall comply with the requirements of 5.3.

6.4.2 Conductor diameter

The conductor diameter shall be measured either:

(a) midway between the closing die and the capstan on the stranding machine, or
(b) at the middle of a portion of conductor, at least 3 m long and more than 5 m from either
end of the conductor, under a tension of at least 2 % of the conductor rated tensile
strength.

The diameter shall be the average of two readings, rounded to two decimals of a millimetre, taken
at right angles to each other at the same location.

The value obtained shall comply with the requirement of 5.4.

6.4.3 Inertness

The requirement of 5.5.7 shall be met.

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6.4.4 Lay ratio and direction of lay

The lay ratio of a given layer of the conductor shall be obtained by dividing the measured lay
length by the diameter of the layer.

The values obtained shall comply with the requirements of 5.5. In addition the direction of each
layer shall be noted and shall also comply with the requirements of 5.5.

6.4.5 Number and type of wires

The number and type of wires shall be confirmed as being in accordance with the conductor
designation stated on the order.

6.4.6 Mass per unit length

The mass per unit length of a 1m sample of conductor shall be determined by using apparatus
capable of achieving an accuracy of ± 0,1 %. The value obtained shall comply with the
requirement of 5.7.3.

6.4.7 Stress-strain curves

6.4.7.1 If the provision of stress-strain curves is agreed between the manufacturer and purchaser
at the time of placing the order, the method described in annex C shall be used.

6.4.7.2 Stress-strain curves shall be supplied as a type test when requested by the purchaser and
shall represent the best knowledge of the behaviour of the conductor under load.

6.4.8 Tensile breaking strength

6.4.8.1 The sample length, between end terminations, shall be at least 400 times the conductor
diameter but not less than 10 m. A shorter length may be agreed between the manufacturer and
purchaser.

6.4.8.2 The breaking strength of the conductor shall be determined by pulling a conductor in a
suitable tensile testing machine having an accuracy of at least ± 1 %. The rate of increase of load
shall be as in C.6.8 of annex C.

6.4.8.3 At the request of the purchaser, an intermediate load may be held for a period during the
test in order to allow tension fittings to be tested at the same time as the conductor.

6.4.8.4 The breaking strength of the conductor shall be determined by the load attained at which
one or more wires of the conductor are fractured. The test shall be considered satisfactory if 95 %
of the rated tensile strength is reached without the fracture of any wires. If fracture occurs within
5 cm of the end terminations before 95 % of the rated tensile strength has been reached, the
fracture shall be deemed to have been caused by the end termination and the test shall be
repeated. In this case, a change in the end terminations shall be considered. If a single wire
fractures more than 5 cm from the end terminations before 95 % of the rated tensile strength has
been reached, two re-tests shall be carried out on samples taken adjacent to the original sample.
Both re-tested samples shall withstand 95 % of the rated tensile strength without the fracture of
any wire.

6.4.9 Stringing test

Where the purchaser requires evidence that the conductor is capable of being installed using the
purchaser's recommended installation method, this may be satisfied by a stringing test, an
example of which is given in annex E. Alternative tests or evidence of satisfactory service
experience may also be agreed.
EN 50182:2001 - 14 -

6.5 Properties of wires after stranding

6.5.1 The specimen of wire shall be taken from the conductor sample and shall be removed
from its position and straightened, care being taken not to stretch it in so doing.

6.5.2 The properties of the individual wires after stranding, including tests on the coating of steel
wires, shall meet the requirements of the wire as specified in the standard referenced in clause 2
with the exceptions:

(a) permitted reductions in wire properties after stranding, given in Table 6, shall apply
together with the following:
The reduction in tensile strength after stranding for ST6C wire, given in Table 6, shall apply
to the mean value of a lot, which shall be interpreted as being the mean value of all the
wires of a given material in the conductor.
(b) for wires where the mean of a lot is specified (AL4 and ST6C), 5 % of individual wire
values may be below the minimum value for an individual wire for tensile strength before
stranding, and above the maximum value for an individual wire for electrical resistivity

Table 6 - Permitted reductions in wire properties after stranding

Material Reduction after stranding

Aluminium (AL1) Tensile strength 5%
Zinc coated steel (ST1A to ST6C) and Stress at 1 % extension (1) : 5%
Aluminium-clad steel (20SA to 40SA) Tensile strength : 5%
Torsion : subtract 2 turns
Elongation (2) : subtract 0,5
Thickness of AL. cladding (SA wire) : 25 % of minimum
Aluminium alloy (AL2 to AL7) None
(1) Measurements of stress at 1 % extension on steel wires other than the centre wire are unreliable. If these
measurements are required to be made on wires other than the centre wire, then the minimum value may be
agreed between the purchaser and the manufacturer.
(2) Example: A minimum elongation value of 3,0 % for wire before stranding is reduced to 2,5 % for wire after
stranding.

6.5.3 Welding of aluminium wires

The manufacturer shall, if required by the purchaser, demonstrate that the method used for
jointing aluminium wires meets the strength requirement of 5.6.5 by performing the tensile test in
the relevant wire standard given in clause 2.

6.6 Properties of grease

6.6.1 Mass per unit length

Using apparatus capable of achieving an accuracy of ± 0,1 %, the mass of grease in a 1 m sample
of conductor shall be determined from the difference between the mass of the conductor with
grease and its mass after removing the grease with the aid of a suitable solvent. The mass of
grease shall comply with the requirement of 5.8.3.

6.6.2 Drop point

A sample of grease removed from the conductor shall meet the drop point requirement of
EN 50326, without preconditioning, after allowing for a reduction of 5 °C due to the sampling
process.